Dubster's 1.8t conversion build

[dubster99]

Haha no its the lawns that need the attention after all that rain we had!

[BurgundyMk3]

K03 wipper snipper would be interesting tho, just a thought.

[quattro5v]

Looking good!

[gner8r]

great build keep it up

[dubster99]

Havnt updated in a while so heres what I have been upto. Stage 3 is a little bit closer!


Gearbox is back on engine and bolted into the car. Plumbed all back up and all looms reinstalled and connected.



Picture of the strengthened clutch fork installed



The high flow manifold installed with the special 8mm nuts that fit a 10mm socket. Still a pain to fit but managed it!




Also trial fitted my polished manifold



Primed the runners before painting too, went for a gloss black look then my injectors arrived from Hungary so I could test fit them and cut down the mounts for the fuel rail since the S3 386cc injectors are shorter than oem.











Also installed a DW65 fuel pump which was pretty straight forward



Quick fixed a split vac hose too



Fitted the Franken TIP and the 3" MAF and realised that I cant use the airbox as I originally wanted to without a bit of messy around so Gav pointed me to a desgin and a site where I could get it and ordered it!

[RolfGolf]

That's a lot of progress Anthony!

[dubster99]

So its all back together now and running!, had it on stands with no axles and had a rattle from thr gearbox. Gav pointed out that it would do this sonI continued putting it back together and it runs. stage 3 baby!! Took it out for a drive but no powersteering and running rough with no o2 sensor it wasnt a very quick drive haha
Heres how my bay looks atm












More to come Enjoy!

[blackers10]

I really like the polished intake

[RolfGolf]

Just went back to the start of your thread and read through it all again Anthony - amazing to see the progress and to think of the 1.6 it used to be ... Inspirational!

[dubster99]

Installed my new south boost gauage in Indigo blue. Hooked it up to my dimmer switch so I can make not as bright if needed

[dubster99]

So once again problems! Installed new O2 sensor, thought it would be sweet to drive and...nope!

Car idles rough and sometimes stalls, last couple of days ive been fiddling with it and researching and ended up capping the nipple under the intake manifold which I forgot to do but still ran rough when I tried to drive it. Would constantly want to stall.

Did a scan and came up with the throttle body code. Seems it wont adapt either through VCDS! All I have done is take the TB off to paint it and reinstalled it. Unsure why all of a sudden it would fail.





heres the fault codes from the VCDS too

[h100vw]

Have you got the N75 and cam position sensor disconnected when you are doing these scans?

I wonder if the TB won't align because of those errors or maybe the cause of those being bad, is also the same as the TB error.

Gavin

N75 fault code, check fuse #34.

Cam Position sensor fault, short to ground.

00515 - Camshaft Position (Hall) Sensor (G40): Short to Ground
Possible Symptoms

Power Loss
Emissions not OK
High Fuel Consumption

Possible Causes

Wiring to Camshaft Position (Hall) Sensor (G40) faulty
Camshaft Position (Hall) Sensor (G40) faulty

Possible Solutions

Check Wiring to Camshaft Position (Hall) Sensor (G40)
Check/Replace Camshaft Position (Hall) Sensor (G40)

16486/P0102/000258 - Ross-Tech Wiki

Also check fuse #43

https://www.dropbox.com/s/0izhn2f4hjn7gmp/AGUmotornic.pdf?dl=0

[dubster99]

Hey guys so not alot of progress due the car running rough. Seems I may need a new throttle body, I hopefully have another throttle body on its way to check if it changes anything.

I did manage to wire up my bora vents after 3 years of having them on the car! Pretty straight forward, not a big statement but something simple none the less

The carnage half way through



And done!


More updates to come when I get this throttle body issue sorted

[dubster99]

Seb was kind enough to send me another throttle body to try and adapt but seemed to come up with the same error codes and unable to adapt. Talks with Seb suggested I find an ecu to match my car and see if swapped it will actaully adapt. Didnt even think of this when I had my old ecu! need to find another ecu ending in CH if anyone knows of one let me know! Haha

[dubster99]

Update! So Gav sent me doen a CH ecu and the thottle adapted first time no issue! Now to figure out how to get the tune onto the CH ecu! And hopefully fixes the running issues Ive had.